Download Aqua-Hot 675-D Installation manual

INSTALLATION MANUAL
© 2011 Aqua-Hot Heating Systems Inc.
CAUTION:
The Aqua-Hot tank and heating loop operate at
0.0 psi (zero pressure system). Air pressure
applied to the tank MUST NOT exceed 20 psi.
Excess pressure will result in internal damage.
CAUTION:
Before welding or plasma cutting on any coach;
it is necessary to disconnect the electric wiring to
the Aqua-Hot System.
Failure to disconnect the wires from the
Aqua-Hot System before using a welder or a
plasma cutter on the coach may cause damage to
the Aqua-Hot.
TABLE OF CONTENTS
Aqua-Hot 675-D Installation Manual
Introduction ........................................................................................................................................... 5
Section 1: Aqua-Hot Hydronic Heating System
Technical Information.......................................................................................................................... 6
Section 2: Aqua-Hot Installation
Installing the Mounting Tray and the Aqua-Hot.............................................................................. 10
Overall Aqua-Hot Dimensions ........................................................................................................... 11
Installing the Expansion Tank ............................................................................................................ 14
Section 3: Hydronic Heating System
Heat Exchanger Location and Clearances......................................................................................... 15
Heat Exchanger Mounting Requirements ......................................................................................... 15
Mounting the Heat Exchangers .......................................................................................................... 16
Sample Heating System Floorplan...................................................................................................... 16
Wiring the Heat Exchangers ............................................................................................................... 19
Plumbing Requirements ....................................................................................................................... 22
Plumbing the Hydronic Heating System ........................................................................................... 22
Section 4: Thermostats
Fresh Water Tank Thermostat ............................................................................................................ 25
Room Thermostats ............................................................................................................................... 26
Section 5: Domestic Water System
Domestic Water System Requirements ............................................................................................. 27
Domestic Water System Plumbing ..................................................................................................... 27
Section 6: Switch Panel
Switch Panel Location .......................................................................................................................... 29
Switch Panel Mounting ........................................................................................................................ 29
Switch Panel Wiring .............................................................................................................................. 29
Section 7: Fuel System
Fuel Filter Location .............................................................................................................................. 31
Fuel System Requirements................................................................................................................... 31
Fuel System Installation ....................................................................................................................... 31
© 2011 Aqua-Hot® 675-D Installation Manual
TABLE OF CONTENTS (CONTINUED)
Section 8: Engine Preheat and Motoraide System
Engine Preheat System Location ........................................................................................................ 34
Engine Preheat Plumbing Requirements ........................................................................................... 34
Engine Preheat Plumbing Installation ............................................................................................... 34
Section 9: Exhaust System
Exhaust System Requirements ............................................................................................................ 36
Installing the Exhaust System ............................................................................................................. 36
Section 10: Electronic Controller Wiring
Electronic Controller Wiring……………………………………………………………...40
Wiring Harness Connection………………………………………………………………41
Connecting the 12 Volt-DC Power……………………………………………………….42
Section 11: Purging the Systems
Purging the Hydronic Heating System............................................................................................... 43
Purging the System by Grounding the Zone Thermostat Connection ......................................... 44
Purging the Domestic Water System.................................................................................................. 44
Section 12: Initial Start-Up
Activating the Aqua-Hot ...................................................................................................................... 46
Appendices:
Appendix A: Wiring Diagram ............................................................................................................. 47
Appendix B: Wire Gauge Information .............................................................................................. 48
Appendix C: Electronic Controller Features .................................................................................... 49
Appendix D: Antifreeze Types ........................................................................................................... 51
Appendix E: Antifreeze Mixture Water Quality Recommendations ............................................. 51
Appendix F: Antifreeze Terms and Mixture Ratio .......................................................................... 52
Appendix G: Measuring Propylene Glycol Using a Refractometer............................................... 52
INTRODUCTION
The Aqua-Hot 675D is a hydronic (water based) heating system, a tank-less hot water system, and a diesel engine preheating system.
The heating system provides moist, quiet, comfortable, interior
heat with up to five separate, thermostatically-controlled temperature zones, and prevents tank and line freezing in the bays.
The tank-less hot water system produces 120 gallons per hour
of continuous, on-demand, hot water.
The diesel engine preheating system circulates the engine’s
antifreeze solution through an internal heating loop in the
Aqua-Hot and pumps it back through the engine, raising the
engine’s temperature from 30°f to 90°F in about 1 hour.
The same heating loop that preheats the diesel engine allows
the Aqua-Hot system to take surplus heat generated by the motor home’s diesel engine while running, and use it to heat the
Aqua-Hot system.
This TribridHot™ designated system uses one or a combination of heat sources to heat FDA-approved Generally Recognized as Safe (GRAS) propylene glycol based antifreeze solution in the Aqua-Hot’s boiler tank.
Danger, Warning, Caution, and Note Boxes:
Danger, Warning, Caution, and Note boxes appear throughout
this manual as a means of alerting the installer to important
information.
! DANGER !
INDICATES THAT PERSONAL INJURY IS LIKELY OR IMMINENT.
CAUTION:
Indicates that serious damage to the heater will occur and
personal injury is possible as well.
WARNING
Indicates that damage to the heater is possible.
NOTE: Indicates information that requires special attention by
the installer.
The 675D uses the motor home engine’s surplus heat while
driving, one 120 Volt-AC, 2000 Watt electric element and one
240 Volt-AC 4500 Watt electric element heat the system when
shore power is available, and a 12 Volt-DC powered diesel
burner provides heat when dry camping. The heat sources can
be used separately or together.
New Low Emissions Technology virtually eliminates smoke
and smell from the exhaust by reducing total hydrocarbon
emission by 82% making Aqua-Hot the cleanest burning diesel
powered hydronic system available.
Please note that all Danger, Warning, Caution, and Note boxes,
appearing as needed throughout this manual, must be reviewed
and adhered to during the installation procedure in order to
avoid potential hazards, which could result in injury, death,
product damage, or property damage.
Should additional assistance be needed, please contact the
Product Application Department at 1-800-685-4298, Monday
through Friday, between the hours of 7:00 AM and 4:00 PM
Mountain Time.
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 1: AQUA-HOT HYDRONIC HEATING SYSTEM
Figure 1
Diesel Burner, Heat Input (Firing Rate) ................................................................................................................................. 56,000 BTU/hr
Diesel Burner, Fuel Consumption (Continuous Operation)........................................................................................................ 0.40 gal/hr
Heater, Voltage/Maximum Power Consumption ......................................................................................................12 Volt-DC/60 watts
Electric Heating Element specifications ........................................................................................................... (2) 120 Volt-AC/2000 watts
Zone Heat Circulation Pump specifications ................................................................................................. (3) 12 Volt-DC/21 watts each
Number of Heating Zones ................................................................................................................... Maximum of 5, plus Engine Preheat
Domestic Water Heating Capacity ........................................................................................................................ Continuous/On-Demand
Dimensions ........................................................................................................................................................... 18.5”H x 18.5”W x 36.75”L
Dry Weight...................................................................................................................................................................... approximately 186 lbs.
Wet Weight ..................................................................................................................................................................... approximately 303 lbs.
NOTE: All vehicle installations must comply with the requirements listed in the Recreational Vehicle Industry Association’s (RVIA) ANSI/NFPA 1192 Handbook for Recreational Vehicle Standards. To receive a copy of this handbook
and other pertinent RVIA Standards, write to: Recreation Vehicle Industry Association, 1896 Preston White Drive,
P.O. Box 2999, Reston, VA 22090-0999, call them at (703) 620-6753, or visit them online at www.rvia.org.
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 1: AQUA-HOT HYDRONIC HEATING SYSTEM
Each Aqua-Hot heating system possesses an I.D. label on the
unit itself. This I.D. label details the specifications of the
heater, to what standard it has been tested, and important
safety notices.
Figure 2
Use a 25
1 inch
3 inches
3 inches
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 1: AQUA-HOT HYDRONIC HEATING SYSTEM
Figure 3
Heating Zone 1
Outlet Port
Domestic Water
Access panel
Interlock
Switch
Zone 1
Circulation
Pump
Zone 3
Circulation
Pump
Zone 2
Circulation
Pump
Engine
Preheat
Pump
Diesel
Burner
Diesel
Burner
Controller
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© 2011 Aqua-Hot® 675-D Installation Manual
Drain Valve
SECTION 1: AQUA-HOT HYDRONIC HEATING SYSTEM
Figure 5
AC Wiring
Air Release
Valve
Zone 1, 2 and 3
Inlet Ports
Expansion Tank
Connection
WARNING!
The Aqua-Hot
tank and heating
loop operate at 0.0
psi (zero pressure
system). Air pressure applied to the
tank MUST NOT
exceed 20 psi. Excess pressure will
result in internal
damage.
Wiring Harness Port
Zone 1, 2 and 3
Outlet Ports
Product ID Label
Engine Preheat
Inlet/Outlet
Ports
Domestic Water
Inlet/Outlet
Ports
Diesel Fuel
Inlet/Outlet
Ports
— Page 9 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 2: AQUA-HOT INSTALLATION
Installing the Mounting Tray and the Aqua-Hot:
The Aqua-Hot must be installed in a compartment that is
completely closed-off from living quarters and accessible
only from the outdoors.
1.
Reference the following illustrations for mounting information:
• Overall Aqua-Hot dimensions - Figure 7
• Mounting tray information - Figure 8
• I.D. Label noting the “Open Access”
clearance requirement for the front of the heater
- Figure 5
• Service access clearances - Figure 6
NOTE: Be sure to complete the following when installing the
Aqua-Hot:
Inspect the area beneath the mounting location to
insure that no structural members will interfere with
the cut-out for the mounting tray.
Verify that an adequate support system has been
provided for the Aqua-Hot.
2.
Cut out the required mounting tray opening. Reference
Figure 8.
3.
Install the mounting tray flange into the cut-out opening.
Reference Figure 8.
.
4.
Insert a #10 machine screw into each of the embossed
holes in the mounting tray (total of six required) and
tighten to secure the mounting tray to the motorhome.
NOTE: Secure the mounting tray into place prior to installing the Aqua-Hot.
Remove the access cover fastener from the AquaHot prior to installation of the Aqua-Hot into the
mounting tray.
Mount the Aqua-Hot securely into the mounting
tray to ensure that the unit does not move or
shift under normal operating conditions
5.
Place the Aqua-Hot into the mounting tray. Reference
Figure 9.
NOTE: Remove the bolt securing the front of the access cover
to the mounting tray; this bolt will need to be reinstalled once the total installation procedure is complete. Remove the access cover.
Figure 6
6
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 2: AQUA-HOT INSTALLATION
Figure 7
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 2: AQUA-HOT INSTALLATION
Figure 8
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 2: AQUA-HOT INSTALLATION
Figure 9
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 2: AQUA-HOT INSTALLATION
Installing the Expansion Tank:
Select a mounting location that allows for easy access
and clear visibility whenever the particular storage
bay door is open.
NOTE: The top of the expansion tank should always be
mounted at least 4 inches higher than the highest point
on the Aqua-Hot. Reference Figure 10.
1.
Mount the expansion tank as illustrated in Figure 10.
2.
Connect and clamp the overflow tubing from the expansion tank to the Aqua-Hot’s expansion tank connection. Reference Figure 10.
3.
Drill a hole in the bay floor and connect (secure with a
clamp) a long enough piece of overflow tubing so that
it can be connected to the top of the expansion tank
and extend through the bay floor.
NOTE: Avoid any dips and bends in the overflow tubing from
the Aqua-Hot to the expansion tank as air can become
trapped in these dips and bends, preventing the expansion of the heating solution from properly depositing
in the expansion tank.
CAUTION:
The Aqua-Hot tank and heating loop operate at
0.0 psi (zero pressure system). Air pressure applied to the tank MUST NOT exceed 20 psi. Excess pressure will result in internal damage.
Figure 10
Expansion Tank
Connection
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
Heat Exchanger Locations and Clearances:
•
Place the heat exchangers so that even heat distribution will be felt throughout the interior of the motor
home. Reference Figure 15A.
NOTE: For single slide-out configurations, it is usually simplest to place a heat exchanger on the opposite side of
the motor home pointing towards the slide-out.
Mounting Requirements:
•
Sufficient ventilation (return-air) must be supplied to
each interior heat exchanger. Reference Figure 16.
NOTE: Ventilation (return air) must be supplied from the living area. Ventilation (return air) MAY NOT be supplied from the bay area.
•
Place the heat exchangers where they will be accessible for potential servicing and cleaning.
NOTE: Mounting the heat exchangers without sufficient ventilation will severely reduce their overall heating performance (heat output).
•
Centralize and position a heat exchanger in the fresh
water storage tank plumbing bay. Reference Figure
13.
In order to provide sufficient ventilation, the return-air
registers must be the same size, or larger, than the
outlet-air registers.
NOTE: In order to achieve the best heating results, place the
heat exchanger as close to the floor of the plumbing
bay as possible (heat will naturally rise).
•
•
Return-air must be supplied from the corresponding
interior heating zones.
Reference Figures 14, 15A, 15B, and 16, for mounting
location information.
Reference Figure 14 for clearance information.
Figure 14
NOTE: An accessory device is available for the Cozy Heat
Exchanger for the purpose of redirecting the airflow
from the heat exchanger. Reference Figures 17 and
18.
Figure 13
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
Figure 15A
Indicates sample mounting locations for the Cozy heat exchangers. Actual placement and quantity vary based on the individual design of the coach. For specific design assistance, contact Aqua
-Hot at 303-659-8221
Figure 15B
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
Mounting the Heat Exchangers:
1.
Cut out a 2.5 inch H x 10 inch W opening for each heat
exchanger outlet and cold-air return register. Reference
Figure 21.
2.
Mount each heat exchanger permanently into place.
Reference Figures 20 and 21.
3.
Install the hot-air outlet and cold-air return registers.
Reference Figure 16.
NOTE: Please note that a return-air register may not be required; however, adequate return-air must be provided to each particular heat exchanger. This means
that the total cross-sectional area of the return-air
opening must be equal to or greater than the crosssectional area of the hot-air outlet opening of the
heat exchanger.
Figure 17
Figure 16
If the toe-kick areas in the motor home are inadequate to
house a heat exchanger for regular installation, a plenum
may be used on the heat exchanger, which can be used with a
smaller vent as seen in Figure 18. The plenum allows only
the desired outlets to be opened by removing the metal insert
on the vent.
Figure 18
Hose to direct
air to vent
Cozy Heat
Exchanger
Plenum
Toe Kick
Board
Vent installed
In toe-kick area
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
Figure 20
Figure 21
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
Wiring the Heat Exchangers:
1. Run two 18-gauge wires, red for (+) and black for (-), from
each particular heating zone’s heat exchanger to the electronic controller. Reference Figure 23.
3.
Insert all heat exchanger wires into the appropriate
terminal/heating zone location on the electronic controller. Reference Figure 22 and Appendix A.
2. Label the wires indicating the heating zone they pertain to
(e.g., Living Room, Bathroom, Bedroom, etc.).
4.
Wire all heat exchangers in a zone in-series. Reference Figure 23 and Appendix A.
5.
Connect all electronic controller wires to the positive
and negative leads of the heat exchanger. Reference
Figures 23 and 24.
Figure 22
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
Figure 23
Figure 22
When wiring the heat exchangers in-parallel, the main 18gauge wire is split to allow the heat exchanger wires to com-
bine with the main wire to be powered or grounded, respectively.
Figure 24
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
Plumbing Requirements:
Once all heat exchangers have been mounted, formulate a
plan for the routing of the plumbing lines from each heating
zone to the Aqua-Hot.
All plumbing lines should be laid as flat as possible, and
any extreme rises in height should be avoided to eliminate
any potential air-traps.
The kitchen and living room heat exchangers (up to 4) must
be plumbed together in-series on “Heating Loop 3.”
Reference Figure 26.
The fresh water tank, and bathroom heat exchangers (up to
4) must be plumbed together in-series on “Heating Loop
2.” Reference Figure 26.
The bedroom heat exchanger must be plumbed on
“Heating Loop 1.” Reference Figure 26.
Use ⅝ inch I.D. (Inside Diameter) plumbing lines for all
heating loops.
Use wide-sweeping elbows or “bend supports” whenever
the plumbing lines may be susceptible to kinking (i.e., 90°
bends).
Heating Loop #1: Zone 1
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
ment (low to high).
Plumbing the Hydronic Heating System:
1.
Lay out the plumbing lines for all heat exchangers.
2.
Label each line with the heating loop number and designate as an inlet or an outlet line.
NOTE: Run all plumbing lines in areas where they cannot
be pinched off or damaged under normal operating
conditions.
4.
NOTE: Reference Figure 28 for visual instructions on connecting PEX-type tubing to each heat exchanger.
Plumbing heat exchangers in this manner will allow
air to escape naturally. If air is trapped in any heat
exchanger, it will significantly reduce the heat exchanger’s overall heating performance (heat output).
Be sure to secure all lines where necessary and apply protective shielding in areas where chafing may
occur.
Rubber Coated/Closed-Type clamps are recommended when securing the plumbing lines.
3.
Connect and clamp the outlet line from the heater to the
lowest port on the heat exchanger with the longest run,
for both heating loops. Reference Figure 27. Then, connect each additional heat exchanger in the same arrange-
Connect and clamp the inlet line from the heater to the
highest port on the last heat exchanger for both heating
loops. Reference Figure 27.
5.
Connect and tighten all interior plumbing lines, outlet
and inlet, to the Aqua-Hot’s appropriate heating loop
ports. Reference Figure 29 and Figure 30.
NOTE: The inlet and outlet plumbing lines can be installed
with a straight fitting or an elbow fitting.
Figure 27
— Page 22 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
Figure 28
Figure 29
Inlet Heating Loop Connection Examples
Barbed Fittings Components
Barb Fittings Components Installed
Compression Fitting Components
Compression Fittings Components Installed
— Page 23 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 3: HYDRONIC HEATING SYSTEM
Figure 30
Outlet Heating Loop Connection Examples
3/4” x 3/4”
Barbed
Fitting
Pex Tube
Pex Insert
Two Constant Tension
Band Clamps
3/4”
Heater
Hose
Pex Tube
Pex Insert
Constant Tension Clamps
Straight Connection Components
Straight Connection Components Installed
90⁰ Connection Components
90⁰ Connection Components Installed
— Page 24 —
© 2011 Aqua-Hot® 675-D Installation Manual
Constant
Tension
Clamp
SECTION 4: THERMOSTATS
2.
Fresh Water Tank Thermostat Locations:
Select a location that will ensure even-heat distribution
throughout the fresh water storage tank bay compartment in
order to prevent the domestic water and plumbing system
from freezing.
Fresh Water Tank Thermostat Wiring:
1.
Typically only the bulb of the thermostat needs to be physically mounted in the area requiring heat (usually in close
proximity to the domestic water pump). Reference Figure
31.
Do not mount the thermostat bulb in a drafty area or along
the ceiling of the bay.
The selected mounting location should allow for easy operator access and should be as low in the bay area as possible.
1.
Select a location for the thermostat bulb in the fresh water storage tank bay compartment.
Run two 18-gauge wires from the thermostat’s
mounting location to the Aqua-Hot’s electronic
controller.
NOTE: It is recommended that the wire numbers in Appendix A be used when installing the Aqua-Hot in order
to assist with differentiating between the separate
heating zones and to aid service personnel with
troubleshooting.
2.
Insert each thermostat wire into the appropriate
terminal/heating zone location in the electronic
controller. Reference Appendix A and Figure 32.
3.
Connect both wires to the appropriate leads of the
thermostat. Reference Figure 31.
Avoid mounting the fresh water tank thermostat’s bulb too
close to the bay heat exchanger.
Fresh Water Tank Thermostat Mounting:
Once the thermostat has been completely wired, permanently mount the thermostat in place. Reference Figure
31.
Figure 31
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 4: THERMOSTATS
Room Thermostat Locations:
Be sure to then turn OFF all interior room thermostats.
Select a location that will insure even-heat throughout each heating zone. Locate each thermostat at approximately chest level, if
applicable.
Room Thermostat Wiring:
1.
NOTE: The selected location should prevent the thermostat from
being affected by:
•
•
•
•
•
drafts or dead spots behind doors and in corners
hot or cold air from ducts
radiant heat from the sun or appliances
heat from concealed pipes and chimneys
unheated or uncooled areas such as an outside
wall behind the thermostat
NOTE: It is recommended that the wire numbers in Appendix
A be used when installing the Aqua-Hot in order to
assist with differentiating between the separate heating zones and to aid service personnel with troubleshooting.
2.
Insert all room thermostat wires into the corresponding
zone number location on the electronic controller.
Reference Appendix A and Figure 32.
3.
Connect all wires to the appropriate leads of each room
thermostat.
Room Thermostat Mounting:
Once the room thermostat has been wired, permanently mount the
thermostat in place.
Run two 18 gauge wires from each room thermostat
mounting location to the Aqua-Hot’s electronic controller..
Reference Appendix A.
Figure 32
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 5: DOMESTIC WATER SYSTEM
Domestic Water System Requirements:
NOTE: Please note that it may be necessary to utilize an accumulator tank within the domestic water system. Reference Figure 34. Although the Aqua-Hot is equipped
with a pressure-relief valve, the use of an accumulator
tank will help prevent excessive “weeping” of the
valve. Manufacturers of pressure-relief valves indicate that excessive weeping of these valves will cause
the “seat” in the valve to deteriorate, and, in turn, the
valve will fail prematurely. For additional information regarding accumulator tanks, please be sure to
reference the Recreational Vehicle Industry Association’s (RVIA) technical publication titled
“Recreational Vehicle Plumbing Systems.” To obtain
a copy of this particular publication, please contact
RVIA at (703) 620-6753 or visit them online at
www.rvia.org.
Use the RVIA-provided table below in order to determine the
proper sizing of pipe and tubing required to insure maximum
efficiency.
The size of water supply piping and branch line shall not be
less than specified in the table below.
NOTE: As stated directly from the ANSI A119.2/NFPA 501C
Standard on Recreation Vehicles, 1993 Edition:
“Piping Systems shall be sized to provide an adequate
quantity of water to each Plumbing Fixture at a flow
rate sufficient to keep the Fixture in a clean and sanitary condition without any danger of back-flow or
siphoning.”
The Aqua-Hot is equipped with a pressure-relief
valve, which releases excessive pressure in the domestic water system, if necessary, as well as a tempering
valve in order to regulate the temperature of the hot
water.
Domestic Water System Plumbing:
1.
Connect a domestic water plumbing line from the domestic
water demand pump/water manifold to the cold water inlet
port on the Aqua-Hot. Reference Figures 33 and 34.
2.
Connect a domestic water plumbing line from the AquaHot’s hot water outlet port to the hot water system’s distribution lines/water manifold. Reference Figures 33 and 34
NOTE: A water heater or ice maker shall not be counted as a
“water-using fixture” when computing pipe sizes.
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 5: DOMESTIC WATER SYSTEM
Figure 33
Domestic Cold
Water Inlet
Figure 34
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© 2011 Aqua-Hot® 675-D Installation Manual
Domestic Hot
Water Outlet
SECTION 6: SWITCH PANEL
1.
Switch Panel Location:
Select a location in the interior of the coach that allows for easy
operator access.
All electric installations, systems, and equipment shall comply
with Article 551, Parts I and III through VI of NFPA 70,
as
well as the regulation of authorities having
jurisdiction and CSA Standard B139.
Run 16-gauge wires from the switch panel to the electronic
controller.
NOTE: It is recommended that the wire colors illustrated in
Appendix A be used when installing the switch panels. This will ensure installation consistency, differentiate between the separate switches and assist service
personnel with troubleshooting. Reference Appendix
B for proper wire-gauge sizing.
2.
Strip and crimp insulated female terminals onto each wire
at the switch panel location.
Switch Panel Mounting:
1.
Cut out a 5” W x 1.25” H opening for the switch panel
plate. Reference Figure 35.
2.
Once the switch panel has been completely wired, permanently mount the switch panel in place.
3.
Move both switches to an OFF position by pressing them
in a downward motion.
NOTE: Be sure to attach “Jumper Wires” where necessary.
Reference Figure 36.
3.
Connect all switch wires to the appropriate switch
connections as illustrated in Figure 36. Reference
Appendix A for additional wiring information.
4.
Insert all switch wires into the appropriate terminal/switch
panel connection on the electronic controller. Reference
Appendix A. Reference Appendix A.
Switch Panel Wiring:
Figure 35
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 6: SWITCH PANEL
Figure 36
Electric High/Low
Switch
3
Electric Element
Switch
6
3
6
Engine Preheat
Switch
3
6
Diesel Burner
Switch
3
6
5
5
5
5
4
4
4
4
Jumper Wire
Jumper Wire
Switch
Pin
Pin# 5# 1
Electronic Controller
To
Harness
38
To Harness Yellow
Yellow Wire
Wire ##38
Pin#
Pin4# 2
Pin#
Pin6# 6
Jumper Wire
Switch
Electronic Controller
Pin# 5
To “Diesel-I”
To Harness Green Wire ##39
39
Pin# 4
To “Diesel-O”
To
To Chassis
Harness Ground
Yellow Wire # 38
Pin# 3
To “IND-LT (+) B3
Pin# 6
To “IND-LT (-) B6
Switch
Electronic Controller
Pin# 5
To “Electric-O”
Pin# 4
To “Electric-I”
Pin# 5
To “Preheat-O”
Pin# 6
To Chassis Ground
Pin# 4
To “Preheat-I”
Pin# 6
To Chassis Ground
Switch
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© 2011 Aqua-Hot® 675-D Installation Manual
Electronic Controller
SECTION 7: FUEL SYSTEM
CAUTION:
Fuel System Installation:
A kinked fuel line (return side) will increase the fuel pressure
to hazardous levels and may cause a fuel line to rupture. A
kinked fuel line could also severely damage the diesel-burner’s
internal fuel system.
Fuel Filter Location:
Mount the fuel filter assembly in a location that provides easy access for replacing the filter element and
for catching any potential fuel spillage when servicing.
1. Run two 1/4 inch fuel lines from the fuel tank inlet and
outlet ports to the Aqua-Hot.
Both fuel lines should be laid as flat as possible and any
extreme rises in height should be avoided in order to eliminate any potential air-traps.
Run both fuel lines in areas where they cannot be pinched,
kinked, or damaged during normal operating conditions.
Run the fuel tank outlet fuel line past the fuel filter location
in preparation for step 7.
Fuel System Requirements:
The diesel fuel supply should be drawn directly from
the vehicle’s main fuel tank or from a separate auxiliary fuel tank, if applicable.
The fuel tank should be equipped with a dedicated
fuel pick-up pipe (outlet port and inlet port). Reference Figure 38.
NOTE: If an auxiliary fuel tank is required, be sure to consult
the ANSI/NFPA 1192 handbook concerning heating
systems’ diesel fuel system specifications.
Also, be sure to reference the ANSI/NFPA 1192 handbook for information regarding fuel distribution system specifications.
Use 1/4 inch I.D. (Internal Diameter) fuel lines.
The combined length of the supply and return fuel
lines should not exceed 100 feet in total length. Reference Figures 39.
2. Be sure to secure all fuel lines where necessary and apply
protective shielding in areas where chafing may occur.
3. Label both fuel lines indicating whether they are an outgoing line or an incoming line.
4. Connect the Aqua-Hot’s fuel lines to the vehicle’s fuel
tank. Reference Figure 38.
5. Install and tighten the appropriate fuel fittings onto the
Aqua-Hot’s fuel ports, as well as the two ports of the fuel
filter. Reference Figures 41.
6. Connect the inlet and outlet fuel lines to the Aqua-Hot’s
fuel port connections. Reference Figure 41.
7. Cut the fuel line at the fuel filter mounting location and
connect the fuel lines as illustrated in Figures 40.
NOTE: Be sure that the flow of fuel through the filter is in the
correction direction as illustrated in Figure 40.
All fuel-fitting hardware (i.e., at the vehicle’s fuel
tank, fuel filter, and Aqua-Hot fuel parts) must be 1/4
inch NPT or greater with a 1/4 inch barbed fitting.
Fuel fittings less than 1/4 inch NPT may restrict fuel
flow, thereby compromising the diesel-burner’s performance.
Figure 38
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 7: FUEL SYSTEM
Figure 39
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 7: FUEL SYSTEM
Figure 40
Reference
Figure 41
Reference
Figure 38
Figure 41
1/4 NPT (F)
Diesel Inlet Port
1/4 NPT (F)
Diesel Outlet Port
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 8: ENGINE PREHEAT & MOTORAIDE SYSTEM
Secure both plumbing lines where necessary and apply
protective shielding in areas where chafing may occur.
Engine Preheat and Motoraide System:
The Aqua-Hot 675-D includes a motoraide feature,
which uses the circulation of the motorhome’s engine to NOTE: Rubber coated/closed-type clamps are recommended
when securing the plumbing lines.
transport the antifreeze and water heating solution from
the Aqua-Hot’s boiler tank to the motorhome’s warm
Use one-piece engine plumbing fittings in order to reengine and back to the boiler tank. The Aqua-Hot 675-D
duce the potential for coolant leaks. It is recommended
also includes an engine preheat feature. This preheat
that pipe thread sealant be used on all engine plumbing
feature provides an easy engine start-up whenever cool
fittings.
weather conditions are present.
Installing the Plumbing:
Location:
1. Install both engine preheat plumbing lines and mark with
The inlet and outlet ports on the vehicle’s engine should
arrows and/or labels at both ends.
be kept as far apart as possible. This will ensure that the
entire engine is thoroughly preheated. Reference Figure
NOTE: The labels should indicate whether the plumbing line is
42.
transporting coolant to the Aqua-Hot or whether it will
be transporting heated coolant to the vehicle’s engine.
NOTE: If assistance is needed in determining the best inlet and
Reference Figure 42.
outlet ports for a specific engine, please contact the particular engine’s manufacturer or chassis supplier.
2. Drain the engine’s coolant.
The engine’s coolant should be allowed to flow as freely
3. Remove the selected inlet and outlet port “plugs” from
as possible to maximize the Aqua-Hot’s engine preheatthe engine.
ing system.
NOTE: Should one or both of the selected engine ports already
The engine’s inlet port is where the heated coolant is
have plumbing fittings attached to them, it may be nectransported to the engine block from the Aqua-Hot. This
essary to “tee” into those existing plumbing fittings.
port should be a high connection point on the engine
Please contact the Aqua-Hot Heating Systems product
block. Reference Figure 42.
application department at 1-800-685-4298 for additional
assistance.
The engine’s outlet port is where the engine’s coolant is
transported to the Aqua-Hot. This port should be a low
4. Install and tighten the plumbing fittings into the inlet and
connection point on the engine block or a pressure outlet
outlet ports on the vehicle’s engine.
port on the engine’s water pump. Reference Figure 42.
Ensure that the engine preheat inlet and outlet hoses are
not placed too close to the engine’s turbo charger.
5. Install and clamp both the inlet and outlet engine plumbing lines/automotive-type heater hoses to the engine’s
plumbing fittings. Reference Figure 43.
Plumbing Requirements:
Use ¾ inch I.D. (Inside Diameter) plumbing lines/
automotive-type heater-hose for the engine preheating
system.
Lay both engine preheat lines as flat as possible and
avoid any extreme rises in height in order to eliminate
the potential for air traps.
Run both plumbing lines in areas where they cannot be
pinched off or damaged during normal operating conditions.
6. Install and tighten a plumbing fitting into the “Inlet” port
on the Aqua-Hot’s engine preheating system.
Reference Figures 1 and 43.
7. Attach and clamp the engine’s incoming plumbing line
to the Aqua-Hot’s outlet connection. Reference Figure
43.
8. Attach and clamp the engine’s outgoing plumbing line to
the Aqua-Hot’s inlet connection.
Reference Figure 43.
9. Verify that all fittings and connections have been tightened, then refill the engine’s coolant system.
— Page 34 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 8: ENGINE PREHEAT & MOTORAIDE SYSTEM
Figure 42
Figure 43
Engine Preheat
Inlet
Engine Preheat
Outlet
— Page 35 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 9: EXHAUST SYSTEM
Do not use galvanized pipe or fittings; only black-iron
pipe and fittings should be used. Reference Figure 47.
The Aqua-Hot’s exhaust is hot and must be kept away from
any heat-sensitive material.
The total length of exhaust pipe should not exceed
27.5 feet with 270⁰ of bends.
DO NOT direct exhaust downward as a fire may result
when parked in dry, grassy areas.
The Aqua-Hot is supplied with a 3 inch and a 4 inch
black pipe nipple (1½ inch diameter) along with a 1½
inch exhaust elbow. Reference Figure 45. These
three exhaust system components MUST BE utilized
with all product installations. Be sure to reference
Figure 46 and 47 to determine which exhaust nipple
should be connected directly to the Aqua-Hot’s exhaust port (i.e., the 3 inch or the 4 inch black pipe
nipple).
Exhaust must not terminate beneath the vehicle or beneath
an open able window or vent.
DO NOT terminate the exhaust pipe within the awning
area of the motor home, if applicable. Be sure to keep the
exhaust away from the slide-out areas.
All Aqua-Hot exhaust system installations MUST utilize the
two black pipe nipples and the black pipe elbow, which are
provided with the heating system, in the configuration best
suited for the particular recreational vehicle application. Failure to conform could create a hazardous situation and will void
the Aqua-Hot’s ETL product listing.
NOTE: Refer to “Internal Combustion Engine Exhausts and
Vehicle Wall Openings” in RVIA’s ANSI/NFPA
1192 Handbook for the Recreational Vehicle Standards, as well as the National Fire Protection Association’s (NFPA) 1192 Standard on Recreational Vehicles for additional information.
NOTE: Should the particular application require more than
27.5 feet of exhaust pipe, please contact the Aqua-Hot
Heating Systems Product Application Department at 1
-800-685-4298 for assistance.
Installing the Exhaust System:
1.
Run the exhaust pipe to the driver’s side or the rear of
the vehicle and ensure that the exhaust fumes cannot
enter into the passenger compartment. Be sure to
keep the exhaust away from the slide-out areas.
2.
Be sure to secure the end of the exhaust pipe to the
vehicle with the proper exhaust hanger/support hardware.
Exhaust System Requirements:
The exhaust must be able to freely exit away from the
vehicle without any obstructions.
Angle the exhaust pipe towards the rear of the vehicle
so that the exhaust fumes will naturally move away
while the vehicle is in motion. Reference Figure 45.
Use a minimum 1-3/4” ID automotive-type exhaust
piping and avoid bends, if possible. Reference Figures 44 and 47.
A maximum of 270º exhaust pipe bends are allowed.
Reference Figure 44.
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 9: EXHAUST SYSTEM
Figure 44
1.7
5
NOTE: A maximum of 27.5 feet with three 90⁰ bends are
allowed in the exhaust pipe. A minimum of 1.75”ID automotive type exhaust pipe may be used.
Figure 45
© 2011 Aqua-Hot® 675-D Installation Manual
— Page 37 —
SECTION 9: EXHAUST SYSTEM
Figure 46
— Page 38 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 9: EXHAUST SYSTEM
Figure 47
3” Black Pipe
Nipple Installed
Black Pipe Elbow
4” Black Pipe
Nipple Installed
2” Automotive
Type Exhaust Pipe
— Page 39 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 10: ELECTRONIC CONTROLLER WIRING
Electronic Controller Wiring:
NOTE: Please reference Appendix A for specific wiring information.
Most electronic controller thermostat and switch connections
possess an “(I)” or an “(O)” symbol. The “(O)” symbol indicates a positive 12 Volt-DC output to a particular thermostat or
switch, while the “(I)” symbol indicates a positive 12 Volt-DC
input signal from a particular thermostat or switch. The 12
Volt-DC output signal is always present as long as the electronic controller is powered by a 12 Volt-DC power source,
while the 12 Volt-DC input signal is only present whenever a
switch is activated or whenever a thermostat is calling for heat.
Reference Appendix A.
All electronic controller fan power connections (and two switch
connections) illustrate a “(+)” or a “(-)” symbol, which indicates that they are polarity-sensitive. Therefore, be sure to use
care when wiring these particular components to the electronic
controller.
Each heating zone “FAN” circuit can supply up to 2.0 Amps of
direct current. This 12 Volt-DC power source allows for multiple Cozy III heat exchangers to be wired “in-parallel”. Reference Figure 44 and Appendix A..
NOTE: A maximum power consumption of 24 Watts can be
supplied by the electronic controller for each “FAN”
heating zone.
Heating Zone 1 is reserved electrically for the “Bedroom
Heating Zone” (Heating Loop 1) ONLY.
Heating Zones 2, 3, and 4 are reserved electrically for the
“Bathroom and Fresh Water Tank Heating Zone” (Heating
Loop 2) ONLY.
Heating Zone 5 is reserved electrically for the “ Living Room
and Kitchen Heating Zone” (Heating Loop 3) ONLY.
All switch connections are to be wired directly to the
Aqua-Hot’s interior switch panel. Reference Figures 31 and
Appendix A. Both the “IND-LT (+) B3” and the “IND-LT(-)
B6” connections on the electronic controller are reserved
electrically ONLY for the diesel-burner switch indicator light
connections.
The Aqua-Hot’s electronic controller is designed to work with
most electronic room thermostats; however, the chosen thermostat must produce a constant 12 Volt-DC output signal and
must receive its 12 Volt-DC power supply from the electronic
controller (i.e., “THERM-O”) in order to ensure that the thermostat and electronic controller are properly fuse protected.
Figure 48
— Page 40 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 10: ELECTRONIC CONTROLLER WIRING
CAUTION:
gauge be determined and utilized.
DO NOT activate the diesel-burner until the antifreeze and
water heating solution has been added to the boiler tank and the
heating system has been completely bled of air. Operating the
Aqua-Hot without the antifreeze and water heating solution
will cause serious damage to the Aqua-Hot’s boiler tank.
Be sure to protect against accidental shorting (i.e.,
chassis shorting) by incorporating a 20-Amp rated inline fuse into the power wire at the battery location.
Reference Figure 50.
WARNING
All electric installations, systems, and equipment
shall comply with Article 551, Parts I and III through
VI of NFPA 70, as well as the regulation of authorities
having jurisdiction and CSA Standard B139.
DO NOT connect the 12 Volt-DC power to the Aqua-Hot if
the vehicle requires welding. Electrical welding will cause
serious damage to the diesel-burner controller and the AquaHot’s electronic controller.
Wiring Harness Connection:
NOTE: Reference Appendix B for proper wire-gauge sizing.
Please note that under full-load conditions, the AquaHot can draw as much as 20 Amps of DC current.
Because the Aqua-Hot is designed to shut down in
the event that the DC voltage level drops too low to
properly operate, it is imperative that the proper wire
1.
Attach the wiring harness connectors to the electronic controller. Reference Figure 43 and Appendix A.
2.
Tighten the screw-type fasteners on the terminal strips to
secure them to the electric controller. Reference Appendix
C.
Connect corresponding 9 and 16 pin connectors from wiring harness
Figure 49
Wiring Harness Connectors
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© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 10: ELECTRONIC CONTROLLER WIRING
1.
Calculate the necessary wire gauge for the 12 Volt-DC power
and ground wires.
A. Determine the total maximum amperage draw of the
Aqua-Hot heating system by adding the total maximum Amps of the installed heat exchangers (consult
the heat exchanger manufacturer for Amp-draw information) to the Aqua-Hot heater’s 22 Amps.
NOTE: Each heating zone “FAN” circuit can supply up to 2.0
Amps of direct current. Each Aqua-Hot Cozy heat
exchanger draws .23 Amps of direct current.
For example, an Aqua-Hot heater with six Aqua-Hot
Cozy heat exchangers draws a total of 23.38 Amps
((6x.23)+22).
4.
5.
Connecting the 120 Volt-AC Power:
1.
Run two 12-2 ROMEX wires, with grounds, from two over
-current protected (20Amp circuit breaker required) 120
Volt-AC power supplies, through the Aqua-Hot’s cable
clamp fitting and to the appropriate terminal block. Appendix A and Figure 50.
2.
Secure the wires into their terminals by tightening the corresponding screw on the terminal block. Tighten the
terminal screws to 5 inch-pounds using a slotted screw
driver blade no larger than 1/8”.
3.
Re-install the terminal block access cover and tighten the
screws securing the cover to the Aqua-Hot.
B. Determine the total length of wire required to connect
the Electronic Controller to the vehicle’s battery.
C. Reference Appendix B with the total Amps and
length of wire to determine the necessary wire gauge.
For example, an Aqua-Hot heater with 6 Aqua-Hot
Cozy heat exchangers with the Electronic Controller
placed 15 feet from the vehicle’s battery would require an 8-gauge wire.
2.
3.
Run and connect two wires –– one red (+) wire and one
black (-) wire (power and ground), from the vehicle’s
main battery disconnect to the Aqua-Hot’s electronic controller. Reference Appendix A and Figure 51.
Attach the DC power wires onto the appropriate terminal/
battery connections on the electronic controller. Reference
Appendix A.
Connect both power and ground wires directly to the vehicle’s main battery disconnect.
NOTE: A ferrule is required if stranded wire is being used to
connect to the terminal block.
Figure 50
Label the wires indicating whether they are a power or a
ground wire.
Figure 51
Main Battery
Disconnect
— Page 42 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 11: PURGING THE SYSTEMS
WARNING
Purging the Hydronic Heating System:
Only propylene glycol based “boiler” type antifreeze
deemed “GRAS” (Generally Recognized as Safe) by the
FDA shall be used in the Aqua-Hot’s hydronic heating system. Failure to use the above specified antifreeze type
could result in serious injury or death.
CAUTION:
Ensure that the overflow tube is connected from the AquaHot’s expansion tank connection to the expansion tank’s bottom connection and from the expansion tank’s top connection
through the overflow tube hole in the motor home’s bay floor
prior to beginning this antifreeze and water heating solution fill
procedure. Failure to do so could result in an antifreeze spill in
the motor home’s bay. Reference Figure 10.
Figure 52
In order to provide the best freeze protection, boil-over protection, and anti-corrosion and rust protection, a 50/50 mixture of
“GRAS” approved propylene glycol antifreeze and water is
recommended.
Reference Appendices C through E for additional information
regarding the antifreeze and water heating solution. Be sure to
use a “GRAS” boiler-type propylene glycol based antifreeze
rather than an RV and Marine antifreeze or an automotive antifreeze/coolant.
If assistance is needed in selecting an appropriate antifreeze,
please contact the Aqua-Hot Heating Systems Product Application Department at 1-800-685-4298.
1.
Open the Aqua-Hot’s drain valve located at the front of the
heater. Reference Figure 53.
2.
Connect a piece of 1/2 inch PEX-type tubing to the drain
valve. This piece should be long enough to transport the
antifreeze and water heating solution from its source to the
Aqua-Hot.
NOTE: The Aqua-Hot’s boiler tank must be filled with the antifreeze and water heating solution through the drain
valve and not through the top of the unit, in order to
avoid air traps. Reference Figure 53.
Figure 53
Drain Valve
— Page 43 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 10: PURGING THE SYSTEMS
3.
4.
5.
Fill the Aqua-Hot completely with the 50/50 mixture of
antifreeze and water heating solution. This will take approximately 16 gallons; look for the solution to enter the
overflow tube attached to the expansion tank connection
on top of the Aqua-Hot.
When refilling, open the air-release valve located on the
expansion tank connection to release air pockets. Reference Figure 52. Hold the valve open until all air is released. Be sure the valve is closed when finished by handtightening. Look for the solution to enter the overflow
tube attached to the expansion tank connection on top of
the Aqua-Hot.
7. Repeat steps 5 and 6 for both heating loops until all air has
been completely bled from the entire heating system.
NOTE: All air is bled from the heating system when all
plumbing lines are free of air. Reference Figure 26.
8.
Once the systems have been purged, disconnect the
alligator clips from the ground source and the circulation
pump’s wires. Reconnect the pump’s wires as originally
configured. Reference Figure 54.
9.
Check the Aqua-Hot’s expansion tank and top it off to the
cold level mark with the 50/50 antifreeze and water
mixture, if necessary.
Close the drain valve.
Purging the System by Grounding the Zone
Thermostat Connection:
1. Ensure that the boiler tank has been filled with the appropriate 50/50 mixture of antifreeze and water heating solution.
2. Locate the heating zone circulation pumps. Reference
Figure 54.
3. Take the circulation pump’s blue (negative) wire and disconnect it from the connector of the opposing wire. Reference Appendix A.
4. Connect an alligator clip to the spade terminal on the circulation pump’s blue (negative) wire and clip the opposite end of the cable to a ground source.
10. Ensure that each circulation pump’s wiring has been
returned to its original configuration. Reference Figure
54.
Purging the Domestic Water System:
Verify that the domestic water tank contains fresh water prior
to bleeding the fresh water system.
1.
Ensure that the vehicle’s domestic water pump has 12 Volt
-DC power, then activate it by opening each hot water faucet, one at a time, and running the water until all air is
purged from the domestic water system.
2.
Once the domestic water system is completely bled, check
for leaks in the domestic water system.
NOTE: The circulation pump will activate as soon as the
pump is connected to a ground source; therefore, disconnect the alligator clip from the ground source during the antifreeze and water heating solution filling
procedure.
5. Allow the circulation pump to operate for approximately 1
-3 minutes in order to purge the corresponding heating
loop, then remove the alligator clip from the ground
source.
6. Open the drain valve and completely fill the Aqua-Hot’s
boiler tank with additional antifreeze and water heating
solution.
— Page 44 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 10: PURGING THE SYSTEMS
Figure 54
Zone 1
Circulation Pump
Zone 3
Circulation Pump
Zone 2
Circulation Pump
— Page 45 —
© 2011 Aqua-Hot® 675-D Installation Manual
SECTION 12: INITIAL START-UP
Activating the Aqua-Hot:
1.
Reinstall the Aqua-Hot’s main access cover and the
fastener, which secures the front of the Aqua-Hot’s
access cover to the mounting tray.
NOTE: The main access cover must be installed prior to operation; a safety switch exists, which will prevent the
Aqua-Hot from operating whenever the main access
cover is not properly installed.
2.
Move the diesel burner switch to the ON position for
approximately ten seconds ONLY, then switch it
OFF.
NOTE: This procedure will purge the diesel-burner’s fuel
system by allowing the heater’s fuel pump to complete its normal 30-150 second shutdown/purge cycle.
3.
After the purge cycle has ended, repeat once more.
4.
Move the diesel-burner switch to the ON position and
leave it on in order to activate the diesel-burner.
NOTE: It will take approximately 10 seconds before the diesel
-burner will ignite and exhaust can be heard exiting
the heater.
Allow approximately 10-20 minutes for the Aqua-Hot
to reach normal operating temperature (approximately
190°F).
5.
Move the Aqua-Hot’s electric element switch to the
ON position in order to supply 120 Volt-AC power to
the electric heating element.
NOTE: Both the 12 Volt-DC powered diesel-burner and the
electric heating element are thermostatically controlled. Either or both heating sources will automatically maintain the temperature of the boiler tank’s
antifreeze and water heating solution.
The Aqua-Hot is now ready for normal operation and use.
— Page 46 —
APPENDIX A: WIRING DIAGRAM
— Page 47 —
APPENDIX B: WIRE GAUGE INFORMATION
— Page 48 —
APPENDIX C: ELECTRONIC CONTROLLER FEATURES
Secondary 12 Volt-DC Battery Connection:
The electronic controller is equipped with two 12 Volt-DC power source connections, which allow for a secondary 12 Volt-DC battery connection. This 12 Volt-DC battery connection is a product-safety feature that should be utilized whenever the Aqua-Hot’s
main 12 Volt-DC power supply is connected to a battery disconnect switch. This feature will ensure that the Aqua-Hot will be protected in the event that the primary power is interrupted while the Diesel-Burner is operating (e.g., during a burn-cycle). This secondary 12 Volt-DC battery connection will ensure completion of the required 3-minute “purge cycle” of the Aqua-Hot’s diesel-burner.
Terminals Strips with Screw-Type Fasteners:
The electronic controller utilizes terminal strips/plugs that are equipped with screw-type fasteners, which are molded directly into
the terminal strip/plug, itself. This will ensure a positive mechanical connection between the electronic controller and all wire harnesses attached to it.
— Page 49 —
© 2011 Aqua-Hot® 675-D Installation Manual
APPENDIX C: ELECTRONIC CONTROLLER FEATURES
“Low Voltage Reset” Feature:
Whenever the Aqua-Hot’s DC power is interrupted, the “low voltage reset” red indicator light on the electronic controller will illuminate.
Reset the electronic controller by pressing the “low voltage reset” button on the electronic controller (use a thin, straight, nonmetallic
object to access the button through the faceplate) or by turning OFF the diesel-burner switch on the interior switch panel for approximately 30 seconds, then turning the switch back ON.
PUMP-3
— Page 50 —
© 2011 Aqua-Hot® 675-D Installation Manual
APPENDIX D: ANTIFREEZE TYPES
The following information addresses the necessary usage of
a propylene glycol based “boiler” type antifreeze in the Aqua
-Hot. Propylene glycol is a safer alternative to the more
toxic ethylene glycol antifreeze; however, as mandated by
IAPMO (International Association of Plumbing and Mechanical Officials), only those propylene glycol based
“boiler” type antifreezes deemed “Generally Recognized as
Safe” (GRAS) by the FDA should be utilized.
the Aqua-Hot’s Hydronic Heating System. This type of antifreeze is not formulated to transfer heat, which is essential to
the heating system’s functionality and does not contain rust
inhibitors. Please note, however, that RV & Marine antifreeze can be utilized to winterize the Aqua-Hot’s Domestic
Hot Water Heating System.
Because of the significant impact various types of antifreeze
can have on a hydronic heating system, including the level of
safety provided, it has been recognized that there is a need to
provide an explanation regarding two additional prominent
types of antifreeze/coolant available. The following information should be utilized as an educational means of ensuring that the proper type of propylene glycol based antifreeze
is selected:
These types of propylene glycol based antifreeze products
are formulated specifically to protect automotive engines
against corrosion, freezing temperatures, and overheating.
They also have excellent heat transfer and thermal conductivity characteristics. Although these types of antifreeze
products are considered less toxic and safer than ethylene
glycol for people, pets, and the environment, they are not
“Generally Recognized as Safe” (GRAS) rated by the FDA.
Therefore, they must be marked with a “harmful if swallowed” warning. This additional warning is required because these types of antifreeze products contain high levels
of chemical rust inhibitors. Due to their potentially hazardous properties, they should never be used in the Aqua-Hot’s
Hydronic Heating System.
RV & Marine Antifreeze:
These types of propylene glycol based antifreeze products
are formulated specifically for “winterizing” applications
only. Although RV & Marine antifreeze is often “Generally
Recognized as Safe” by the FDA, it should never be used in
Automotive Antifreeze/Coolant:
APPENDIX E: ANTIFREEZE MIXTURE WATER QUALITY RECOMMENDATIONS
In order to ensure maximum performance and longevity of
an Aqua-Hot heating system’s boiler tank and associated
components, it has been determined that there is a need to
use distilled, de-ionized, or soft water in combination with
concentrated propylene glycol for the Aqua-Hot’s antifreeze
and water heating solution. Please note that this is only necessary when mixing concentrated propylene glycol antifreeze
with water; suppliers of pre-mixed antifreeze are responsible
for the use of high-quality (distilled, de-ionized, or soft) water when preparing their antifreeze for sale.
Hard water possesses a high-level of calcium and magnesium
ions, which deplete the propylene glycol antifreeze’s corrosion inhibitors. This, in turn, causes the antifreeze and water
heating solution to begin turning acidic, which can corrode
the Aqua-Hot’s Boiler tank and associated components prematurely. Therefore, concentrated propylene glycol should
be diluted with distilled, de-ionized, or soft water which is 80
ppm or less in total hardness. The local water agency should
have up-to-date water quality reports which should indicate
if the local tap water is within this guideline.
— Page 51 —
© 2011 Aqua-Hot® 675-D Installation Manual
APPENDIX F: ANTIFREEZE TERMS AND MIXTURE RATIO
Propylene Glycol Based Antifreeze Solution:
The following information addresses the process of selecting
a propylene glycol based antifreeze solution that provides
adequate freeze, boiling, and rust/anti-corrosive protection.
A propylene glycol antifreeze solution that is 35% to 50%
propylene glycol is recommended. Antifreeze solution with
50% propylene glycol will result in a freeze point of approximately -28ºF and a boil point of approximately 222ºF.
NOTE: As the installer of this Aqua-Hot system, you must
refer to the information and chart in Appendix E
to determine the percentage of propylene glycol
your antifreeze solution should contain for the
level of protection you require.
Aqua-Hot sells CAMCO propylene glycol based antifreeze
solution in the following packages:
boiling point is reached; it is at this point that the liquid turns
to a gas and is expelled to prevent the heating system from
overheating. Each time the boiling point is reached, a loss of
efficiency occurs because the heat produced is expelled
rather than utilized for the function of the heating system.
Therefore, a higher boiling point is desired in order to combat the loss of efficiency, which allows the antifreeze to
transport the heat created from the internal process throughout the motorhome where it can be utilized productively
rather than dissipating due to its change from a liquid to a
gas.
Rust and Anti-Corrosive Inhibitors:
Another major function of antifreeze solution is to provide
protection to the internal metal components of the Aqua-Hot
hydronic heating system from corrosion and rust. Antifreeze
is able to perform this function by the addition of rust and
anti-corrosive inhibitors, which are designed specifically to
activate in a water solution.
The following information should be utilized for the purpose
of clarifying some terms commonly associated with antifreeze.
Summary:
Freeze Point and Burst Point:
Antifreeze solution has three basic functions: freeze protection, boil-over protection, and anti-corrosion and rust protection.
NOTE: Propylene glycol based antifreeze solution is not
100% propylene glycol. It is a mixture of propylene
glycol, rust and anti-corrosive inhibitors, and water.
Antifreeze solution lowers the freezing point of any liquid, to
which it has been added, by preventing the formation of ice
crystals; however, as the ambient temperature continues to
decline, the water in the solution will attempt to attain a solid
state. The point in which the water begins to solidify is
termed the “Freeze Point.” Although the water in the solution has begun to freeze, producing a “slushy” consistency,
the antifreeze in the solution will continue to combat the
normal expansion of the solution as it freezes. The point in
which the solution can begin to expand, due to colder temperatures, is called the “Burst Point.” Once the solution
reaches the burst point, the potential is present for ruptured
pipes to exist. The burst point of the antifreeze and water
heating solution is dependent upon the brand of propylene
glycol antifreeze employed.
Boiling Point:
The Aqua-Hot utilizes the propylene glycol based (PPG)
antifreeze and water heating solution as a transportation
means for the heat produced from the internal processes.
The PPG antifreeze solution absorbs the heat created until its
— Page 52 —
PPG Antifreeze solution is also primarily responsible for
heat transfer; however, propylene glycol itself does not possess acceptable heat transfer characteristics. Therefore, as
water is an excellent heat conductor, it is added to the mixture. PPG antifreeze solution , mixed with water, that is 35%
to 50% propylene glycol is recommended to provide the best
performance combination of the aforementioned functions.
If excess propylene glycol exists within an antifreeze and
water heating solution, the water’s heat absorption properties
are compromised, which could ultimately inhibit the AquaHot from providing adequate domestic hot water and interior
heating.
Additionally, if the antifreeze and water heating solution
contains over 70 percent propylene glycol, the freezing point
is actually raised, resulting in less freeze protection. Please
reference the attached graphical representation regarding the
percentage of antifreeze to water and how it directly affects
the solution’s freezing point.
APPENDIX F: ANTIFREEZE TERMS AND MIXTURE RATIO
— Page 53 —
APPENDIX G: MEASURING PROPYLENE GLYCOL USING A REFRACTOMETER
CALIBRATE
THE
REFRACTOMETER
Aqua-Hot Part Number MSX-907-162
Figure 1
Calibration Screw
Eyepiece
Daylight Plate
Assembly
Main Prism
Assembly
© 2011 Aqua-Hot® 675-D Installation Manual
APPENDIX G: MEASURING PROPYLENE GLYCOL USING A REFRACTOMETER
USING
THE REFRACTOMETER TO TEST ANTIFREEZE SAMPLE
Warning
1.
Use extreme caution in gathering your antifreeze sample. When draining the Aqua-Hot heating system.
extremely hot liquid may be in the Boiler Tank and could cause personal injury.
Basic Operation
1. Open daylight plate, and place
2-3 drops of the sample on the
main prism. Close the daylight
plate so the liquid sample spreads
across the entire surface of the
prism without air bubbles or dry
spots. Allow the sample to rest
on the prism for approximately
30 seconds before going to step
#2. (This allows the sample to
adjust to the ambient temperature
of the refractometer).
2. Hold daylight plate in the direction
of a light source and look into the eyepiece. You will see a circular field
with graduations down the center (you
may have to focus the eyepiece to
clearly see the graduations). The upper portion of the filed should be blue,
while the lower portion should be
white.
3. Take the reading where the
boundary line of blue and white
cross the graduated scale. The
scale will provide a reading of the
freezing point of antifreeze solution and the propylene glycol
concentration. Clean the prism
carefully using a damp soft cloth.
Do NOT immerse in water.
NOTE: Refractometers may have more than one scale. Make sure you are reading the scale marked
“Propylene” for measuring the antifreeze solution in the Aqua-Hot system.
© 2011 Aqua-Hot® 675-D Installation Manual
15549 East Highway 52 | Fort Lupton, CO 80621
Toll free: 800.685.4298 | phone: 303.659.8221 | fax:303.857.9000
www.aquahot.com
LTE-907-690 Rev B